Stackable rebar support chair

ABSTRACT

A stackable rebar support chair having a support chair and a support plate detachable to each other. The support chair includes a base having multiple upstanding posts and downwardly extending legs designed to suspend the base above surface. The base can include multiple holes to permit the free flow of concrete around the support chair. Multiple centering supports can connect to and extend between each of the upstanding posts and an upper surface of the base to provide support to the posts and to permit gravity to assist positioning the supported rebar to a generally central position on the base. The base can include ribs extending from its lower surface to provide support to the base from the weight of the rebar. The support plate can include multiple generally upright pegs having recesses to receive the legs.

FIELD OF THE INVENTION

The present invention relates generally to an apparatus for positioning and supporting rebar and other reinforcement devices a distance above a surface. More specifically, the invention relates to a stackable rebar support chair having centering supports designed to automatically position the rebar on the support chair and to support upstanding posts used to stack multiple support chairs.

BACKGROUND OF THE INVENTION

The use of various rebar support chair devices is known in the prior art. However, all of these devices fail to provide a stackable rebar support chair having centering supports designed to automatically position the rebar on the support chair. They also lack centering supports that are designed to support upstanding posts that are used to stack multiple support chairs on top of each other.

BRIEF SUMMARY OF THE INVENTION

The invention in particular embodiments has base having a number of legs extending downwardly from a lower surface and a number of corresponding upstanding posts extending generally upwardly from an upper surface. Each of the legs can have a generally pointed end or a blunted end for abutment against various surfaces. Each of the posts can include a socket extending axially therein for detachably receiving a corresponding leg of another rebar support chair such that multiple rebar support chairs can be stacked upon one other to permit the layering of multiple layers of rebar.

In one embodiment of the invention there is at least one centering support connected to and extending between each of the upstanding posts and the upper surface of the base. Each of the centering supports is designed to permit gravity to assist the supported rebar to a generally central position on the base, thereby facilitating proper weight distribution and alignment. Additionally, the centering supports reinforce the upstanding posts when the rebar support chairs are stacked on top of each other. In another embodiment of the invention, there are multiple centering supports connected to and extending between each of the upstanding posts and the base.

In another example embodiment of the invention, the base can include at least one hole extending through it to permit the free flow of concrete, cement or any other type of construction material. In another embodiment of the invention there are multiple holes extending through the base such that at least a pair of cross supports is formed extending between the upstanding posts and legs. In this embodiment of the invention, centering supports can be attached to and can extend between the upstanding posts and the cross supports. Additionally, ribs may be positioned on a lower surface of the base, and/or base and cross supports to provide additional structural rigidity.

In yet another embodiment of the invention a support plate can be attached or fixed to the legs to permit the rebar support chair to be used on generally soft surfaces. The support plate includes a generally planar bottom and multiple generally upright pegs having recesses to receive the legs. At least one support can be connected to and extending between each of the generally upright pegs and an upper surface of the support plate to support the legs and upright pegs when the rebar is disposed on the rebar support chair.

The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 is an exploded view of the rebar support chair and support plate supporting rebar.

FIG. 2 is a perspective view of the rebar support chair;

FIG. 3 is a bottom view of the rebar support chair;

FIG. 4 is bottom perspective view of the rebar support chair;

FIG. 5 is a cross section view along line A-A of FIG. 1;

FIG. 6 is a side view of the rebar support chair;

FIG. 7 is a perspective view of a support plate;

FIG. 8 is a side view of the support plate, upright pegs and support another embodiment of the invention having a noise generating assembly disposed in the weighted body; and

FIG. 9 is a top view of the support plate;

FIG. 10 is an exploded view of two support chairs stacked together.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to FIGS. 1-10, a stackable rebar support chair, noted by the numeral 10 is provided for supporting rebar above a surface such as dirt, rocks, sand, and the like. Referring to FIG. 1, the stackable rebar support chair 10 includes a chair support 12 and a support plate 30 made of a generally rigid material such as plastic or metal. However, any type of material capable of supporting rebar and other construction materials can be utilized. In one example embodiment, the chair support 12 and the support plate 30 can be detachably coupled together for supporting rebar on soft surfaces such as sand. However, the support chair 12 can also be used without the support plate 30 to support rebar or other construction materials above harder surfaces such as rock, cement or concrete.

Referring now to FIG. 2, the support chair 12 includes a base 14 that is oriented generally horizontal to the surface or ground. The base includes an upper surface 15 and a lower surface 16 oriented generally parallel to each other. The base 14 can include at least one hole 18 extending through the upper 15 and lower 16 surfaces to define at least one cross support 19. The at least one hole 18 permits the free flow of concrete or cement around the support chair 12. The free flow of concrete or cement prevents shear plans from developing and impacting the quality of the hardened concrete or cement. As illustrated in the Figures, multiple holes can be formed in the base 14 to define multiple cross supports. The size and shape of the holes can vary depending upon the amount of free flowing concrete desired.

Referring to FIGS. 1, 2, and 4-6, the base 14 includes multiple upstanding posts 20 extending from its upper surface 15 and multiple downwardly extending legs 21 extending from its lower surface 16. Respective upstanding posts 20 and legs 21 are generally axially aligned to each other and generally perpendicular to the base 14 such that the base 14 is suspended above the ground surface between the upstanding posts 20 and legs 21. In one example embodiment, the upstanding posts 20 and legs 21 are positioned at corners of the base 14. However, the upstanding posts 20 and the legs 21 can be positioned anywhere on the base 14, thus allowing for multiple configurations.

As particularly illustrated in FIGS. 1, 2 and 5, the upstanding posts 20 each include a socket 22 extending therein for receiving a corresponding leg 21 when one support chair 12 is stacked upon another support chair 12. Each of the downwardly extending legs 21 generally have a smaller diameter than the upstanding posts 20 to permit relatively easy insertion into the sockets 22 of the upstanding posts 20. In example embodiments of the invention, the ends of each of the legs 21 can be generally pointed, tapered or blunt.

Referring to FIGS. 1, 2, and 5-6, each of the upstanding posts 20 includes at least one centering support bracket or gusset 24. Each of the centering support brackets 24 extends between and is coupled to the upper surface 15 of the base 14 and an upstanding post 20. Referring particularly to FIG. 6, a pair of centering support brackets 24 forms a V-shape, which is designed to permit gravity assisted positioning of the rebar to a central position on the base 14. By positioning the rebar over the central portion of the base 14, it permits the automatic proper weight distribution over the support chair 12.

Referring to the example embodiment of FIGS. 1 and 2, there can be a plurality of centering support brackets 24 such that there is a centering bracket support system 23 to facilitate centering the rebar and supporting the posts. The centering bracket support system 32 can include a first centering support bracket 24 a and a second centering support bracket 24 b extending between each of the upstanding posts 20 and the upper surface 15 of the base 14 to provide increased structural rigidity to the upstanding posts 20 posts and automatic positioning of the rebar. The first centering support bracket 24 a can extend in a first direction proximate a peripheral edge of the base 14. The second centering support bracket 24 b can extend in a second direction proximate the peripheral edge of the base 14. In one embodiment, the first centering support bracket 24 a and the second centering support bracket 24 b are positioned generally orthogonal to each other.

The centering bracket support system 23 can also include a third centering support bracket 24c that can also extend between each of the upstanding posts 20 and a cross support 19 to provide increased structural rigidity to the upstanding posts 20 and automatic centering of the rebar. In this embodiment, a length of the third centering support bracket 24 c can be greater than a length of the first centering support bracket 24 a and the second centering support bracket 24 b. However, any configuration of length, size, or position of the upstanding posts 20, legs 21, base 14, cross supports 19 and centering support brackets 24, 24 a, 24 b, or 24 c are considered to be within the spirit and scope of the invention and within the knowledge of the inventor and one skilled in the art.

Referring to FIGS. 3 and 4, ribs 26 can extend from the lower surface 16 of the base 14 to provide additional support when the rebar is positioned thereon. The ribs 26 can be positioned on the cross supports 19 or on the cross supports 19 and portions of the base 14 extending around a perimeter of the base 14. In one example embodiment, as illustrated in FIGS. 3 and 4, each of the ribs 26 is connected to and extends between a leg 21 and a central post 27 that extends from the lower surface 16 of the base 14. The use of the centering support brackets 24 and the ribs 26 provide increased structural rigidity to the upstanding posts 20, legs and base 14 such that installers are able to walk on installed support chairs 12 and rebar without fear of shifting the rebar or breaking the support chairs 12.

Referring to FIGS. 7-9, the support plate 30 includes a generally planar panel 32 having a configuration of a rectangle or square. In one embodiment of the invention, the panel 32 will have the same footprint or area as the base 14 such that when the two are connected together the base 14 is position generally parallel over the panel 32. The panel 32 can be constructed with the same generally rigid material as the support chair 12. The thickness of the panel 32 can vary depending upon the amount of support needed during use.

The panel 32 can include a plurality of pegs 34 extending from its upper surface 35 for receiving and support the legs 21. Each of the pegs 34 includes a bore 36 extending therein having a size and shaped to receive each of the legs 21. The legs 21 and the upstanding posts 20 or the legs 20 and the pegs 34 can be loosely fitted together to ensure easy assembly and disassembly or they can be tightly fitted together to ensure that they will not become disconnected during use. In another embodiment, the legs 20 and the pegs 34 can be fixed together such that the support chair 12 and the support plate 30 are one unit.

Referring to FIGS. 7-9, each of the pegs 34 can include a support bracket or gusset 38 extending between and coupled to the pegs 34 and the upper surface 35 of the panel 32 to provide structural rigidity to the legs 21 when they are connected to the support plate 30. Each pair of support brackets 38 extending from each peg 34 includes long axes that intersect in a center of the pegs 34 such that a pair of corresponding support brackets 38 of each peg 34 is generally oriented orthogonally to each other. Additionally, as particularly illustrated in FIGS. 7 and 9, the support brackets 38 of the pegs 34 are disposed proximate a lateral or peripheral edge of the panel 32 such that each support bracket 38 of the pegs 34 lies in a plane generally parallel to a plane of one of the perimeter edges of the panel 32.

In use, the installer decides if the support chair 12 needs to be connected to the support plate 30. If needed, the installer inserts the legs 21 of the support chair 12 into the bores 36 of each of the pegs 34 on the support plate 30. Once the support chair 12 and the support plate 30 are connected the installer lines them in the form where the concrete will be poured. Once in position, the installer lays rebar or other construction material on to the support chairs 12. The V-shape formed by the support brackets 24 extending between each of the upstanding posts 20 and the upper surface 15 of the base 14 cause each rebar to automatically find a center of the support chair 12 between the posts 20 and the legs 21. The installer can also install rebar on the support chairs 12 such that they cross each other or such that a long axis of each of the rebar intersect each other at a center of the support chair 12.

In some uses, where a thicker layer of concrete is needed, there is a need to have multiple layers of rebar. During this use the installer inserts the legs 21 of additional support chairs 12 into the sockets 22 of the upstanding posts 20. The installer is then able to lay pieces of rebar on top of the new layer of support chairs 12. These steps can be repeated until the desired number of rebar in place. Once all of the support chairs 12 and the rebar are in place, the installer is able to pour the concrete. The concrete then flows around the support chairs 12, through the holes 18, between the upstanding posts 20 and the legs 21, and over the support plate 30, thereby ensuring that they are fixed in place. The orientation and number of support brackets 24 and 28 extending between the upstanding posts 20 and the base 14 and between the pegs 34 and the panel 32 ensure that the lower support chairs 12 do not buckle or break under the weight of the rebar and concrete.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. 

1. A stackable rebar chair for supporting rebar above a surface, the stackable rebar chair comprising: a support chair having a base with a plurality of posts extending upwardly and a plurality of legs extending downwardly; and a plurality of support brackets extending between each of the posts and the base, wherein at least two support brackets facilitate the positioning of the rebar in a center portion of the base between the plurality of posts and plurality of legs.
 2. The stackable rebar chair of claim 1, further including at least one socket extending into an end of each of the plurality of posts for receiving legs of a second stackable rebar chair.
 3. The stackable rebar chair of claim 2, wherein each of the sockets is axially aligned with a long axis of the plurality of posts
 4. The stackable rebar chair of claim 1, wherein each of the plurality of legs has a pointed end.
 5. The stackable rebar chair of claim 4, further comprising a support plate having a panel and a plurality of pegs extending upwardly therefrom, each of the plurality of pegs having bore for receiving the pointed ends of the plurality of legs.
 6. The stackable rebar chair of claim 1, further comprising a support plate attached to the plurality of pegs.
 7. The stackable rebar chair of claim 1, further comprising at least one rib disposed on a lower surface of the base.
 8. The stackable rebar chair of claim 1, further comprising a first rib and a second rib extending from a lower surface of the base, wherein the first rib extends between a pair of the plurality of legs and the second rib extends between a second pair of the plurality of legs.
 9. The stackable rebar chair of claim 8, wherein the first and second ribs cross each other.
 10. The stackable rebar chair of claim 8, further comprising a central post extending from the lower surface of the base, wherein the first and second ribs intersect with the central post.
 11. The stackable rebar chair of claim 8, further comprising at least one hole extending through a portion of the base.
 12. A stackable rebar chair for supporting rebar above a surface, the stackable rebar chair comprising: a support chair having a base with a plurality of posts extending upwardly and a plurality of legs extending downwardly; and a centering bracket system disposed to each of the posts and the base to facilitate the positioning of the rebar in a center portion of the base between the plurality of posts and plurality of legs, each centering bracket system including: a first centering bracket extending in a first direction along a peripheral edge of the base; a second centering bracket extending in a second direction along a peripheral edge of the base, wherein the first and second centering brackets are orthogonal to each other;
 13. The stackable rebar chair of claim 12, further comprising a third centering bracket extending toward a center of the base.
 14. The stackable rebar chair of claim 12, further including at least one socket extending into an end of each of the plurality of posts for receiving legs of a second stackable rebar chair.
 15. The stackable rebar chair of claim 14, wherein each of the sockets is axially aligned with a long axis of the plurality of posts.
 16. The stackable rebar chair of claim 12, wherein each of the plurality of legs has a pointed end.
 17. The stackable rebar chair of claim 16, further comprising a support plate having a panel and a plurality of pegs extending upwardly therefrom, each of the plurality of pegs having bore for receiving the pointed ends of the plurality of legs.
 18. The stackable rebar chair of claim 12, further comprising a support plate attached to the plurality of pegs.
 19. The stackable rebar chair of claim 12, further comprising at least one rib disposed on a lower surface of the base.
 20. The stackable rebar chair of claim 12, further comprising a first rib and a second rib extending from a lower surface of the base, wherein the first rib extends between a pair of the plurality of legs and the second rib extends between a second pair of the plurality of legs.
 21. The stackable rebar chair of claim 20, wherein the first and second ribs cross each other.
 22. The stackable rebar chair of claim 20, further comprising a central post extending from the lower surface of the base, wherein the first and second ribs intersect with the central post. 